Absorbent articles with garment-like refastenable seams

ABSTRACT

A disposable absorbent article includes a fastening system that can be repeatedly fastened, unfastened and refastened. The refastenable seams formed by the fastening system components provide a garment-like appearance.

BACKGROUND OF THE INVENTION

The present invention relates to absorbent articles which are adapted tocontain body exudates. More particularly, the invention pertains topant-like disposable absorbent articles having garment-like refastenableseams, and methods of making such disposable absorbent articles.

Current disposable absorbent training pants for children going throughthe potty training stage have proved to be a particularly desirable anduseful product. Such training pants generally include an absorbentchassis including a liquid impervious outer cover, a liquid perviousbodyside liner and an absorbent structure. The training pants furtherinclude stretchable side panels that are permanently bonded to oppositeside edges of the absorbent chassis. The chassis and side panels therebyform a unitary waist opening and two leg openings. The fit of the pantsmay be further enhanced by gathering means along the waist and legopenings.

The components of traditional training pants are permanently seamedtogether to provide a pant product. These products are particularlyappealing to caregivers and are useful in the toilet training processbecause the pant has a very garment-like look. Children identify diaperproducts with babies, and most children do not like being identifiedwith or as babies. Consequently, these children do not want to wear babydiapers, and instead prefer to wear training pants that look like adultunderwear. Thus, the switch from a traditional diaper to a moregarment-like or underwear-like training pant can be an important step inthe toilet training process.

One drawback with current training pants, however, is that the manner ofapplying them is limited to being pulled on like a pant. Applying theproduct like a pant is advantageous in many instances, and isparticularly suited for active, walking children. Even for the samechild, however, there may be times when it would be useful to apply theproduct like a diaper. For instance, it might be more convenient toapply the product like a diaper when there is a desire not to remove thechild's shoes. Because it is difficult to know when a particular mode ofapplying the garment will be needed, it is beneficial to have a garmentthat is adaptable to being used either as a diaper or as a pant. This ispreferable to keeping both types of garments available. A product thatcan be applied either like a diaper or a pant permits the interior ofthe product to be easily checked without having to pull the productdownward.

Thus, it would be desirable to have a disposable absorbent article thatprovides the garment-like or underwear-like look of a traditionaltraining pant yet affords the option of being applied either like adiaper or like a pant.

SUMMARY OF THE INVENTION

In response to the above-referenced unfulfilled need in the art, a newpant-like disposable absorbent article having garment-like refastenableseams and a method of making such a disposable absorbent article havebeen discovered. The absorbent article includes a fastening system thatcan be repeatedly fastened, unfastened and refastened. The refastenableseams formed by the fastening system components provide a garment-likeappearance.

In one embodiment, the present invention pertains to an absorbentarticle including an absorbent chassis that defines a longitudinal axis,a transverse axis, a first or front waist edge and a second or backwaist edge which are parallel to the transverse axis, and opposite sideedges that extend between the front and back waist edges. The absorbentchassis also defines a first or front waist region contiguous with thefront waist edge, a second or back waist region contiguous with the backwaist edge, and a crotch region which extends between and interconnectsthe front and back waist regions. The absorbent chassis includes arectangular composite structure having opposite linear side edgesparallel to the longitudinal axis and opposite linear end edges parallelto the transverse axis. The composite structure includes a bodysideliner, an outer cover bonded to the bodyside liner, and an absorbentassembly disposed between the bodyside liner and the outer cover. A pairof elastomeric side panels is bonded to the composite structure in theback waist region, with each side panel being elastomeric in a directionparallel to the transverse axis. The absorbent article also includes afastening system for releasably securing the absorbent article in apant-like configuration. The fastening system includes first and secondfastening components adapted to releasably engage first and secondmating fastening components. The fastening components are disposed onthe elastomeric side panels and having a length dimension, a widthdimension, and a length-to-width ratio of about 2 or greater. The matingfastening components are disposed in the front waist region andpositioned along the opposite side edges abutting the front waist edge.

The fastening components and the mating fastening components formrefastenable seams for securing the first and second waist regionstogether. The refastenable seams allow the product to be either pulledon like a pant or applied like a diaper. If the training pant becomessoiled during use, the fastening components can be disengaged from themating fastening components to easily remove the training pant from thewaist of the wearer with reduced risk of undesirably soiling the clothesor legs of the wearer. Further, the fastening components can also beeasily disengaged from the mating fastening components to inspect thetraining pant for possible soiling. Thus, the training pant isconfigured to be pulled on or off over the hips of the wearer such asconventional training pants and can be readily applied or removed bydisengaging the fastening components similar to conventional diapers.Moreover, the first and second fastening components can be repositionedif necessary after the training pant has been pulled on over the legsand hips of the wearer.

This embodiment of the invention also provides an absorbent article thatis extremely compatible with high-speed manufacturing processes. Thecomposite structure can be formed as a rectangular shape and theelastomeric side panels joined to the composite structure with theirwaist end edges forming part of the back waist edge of the absorbentarticle.

The design of the absorbent chassis and the fastening componentsprovides the absorbent article with a garment-like appearance. Therefastenable seams in particular can be integrated within the absorbentchassis so that they are flush with the overall exterior product shape.The garment-like seams are thus less likely to disengage inadvertently.The refastenable seams may also be made less noticeable and as a resultmay be made harder for children to open without guidance. Additionally,the fastening system components can be incorporated into the absorbentarticle without interfering with existing outer cover graphics, whichhave become an important interactive toilet training feature in currenttraining pants.

The garment-like fit of the absorbent article can be improved by theincorporation of leg elastic members that are longitudinally alignedalong each side edge of the absorbent chassis. In particularembodiments, the leg elastic members are also axially aligned with themating fastening components. This not only creates an absorbent articlethat is suited for high-speed manufacture, but also advantageouslypositions the mating fastening components at the front of the wearer'sbody. Desirably, the front terminal points of the leg elastic membersmay be located adjacent inner end edges of the respective matingfastening components, for example within about 2 centimeters of themating fastening components, particularly within about 1 centimeter ofthe mating fastening components, and more particularly abutting orslightly overlapping the mating fastening components, and the backterminal points may be located adjacent longitudinally innermost partsof the side panels, for example within about 2 centimeters of thelongitudinally innermost parts of the side panels, particularly withinabout 1 centimeter of the longitudinally innermost parts of the sidepanels, and more particularly at the same location or slightly extendingbeyond the longitudinally innermost parts of the side panels.

Hence, in another embodiment, the present invention pertains to anabsorbent article including an absorbent chassis comprising a bodysideliner, an outer cover bonded to the bodyside liner, and an absorbentassembly disposed between the bodyside liner and the outer cover. Theabsorbent chassis defines a longitudinal axis, a transverse axis, anoverall length dimension, front and back waist edges parallel to thetransverse axis, opposite side edges extending between the front andback waist edges, a front waist region contiguous with the front waistedge, a back waist region contiguous with the back waist edge, and acrotch region which extends between and interconnects the front and backwaist regions. The side edges in the front waist region and crotchregion are aligned with one another parallel to the longitudinal axis.First and second side panels extend transversely outward from theabsorbent assembly in the back waist region. The side panels haveopposite waist end and leg end edges and an average length dimensionthat is about 20 percent or greater of the overall length dimension. Legelastic members are longitudinally aligned along each side edge. Afastening system of the absorbent article releasably secures theabsorbent article in a pant-like configuration. The fastening systemincludes first and second fastening components that are adapted toreleasably engage first and second mating fastening components. Each ofthe fastening components and the mating fastening components have alength dimension aligned generally parallel to the longitudinal axis, awidth dimension, and a length-to-width ratio of about 5 or greater. Thefastening components are disposed on the side panels, and cover about 80to 100 percent of the distance between the opposite edges of the sidepanels. The mating fastening components are disposed in the front waistregion along the opposite side edges abutting the front waist edge. Theleg elastic members are axially aligned with the mating fasteningcomponents.

The positioning of the mating fastening components can also be enhancedby positioning inner side edges of the mating fastening componentstransversely outward from and adjacent to the side edges of the primaryabsorbent structure of the absorbent article. In doing so, the fasteningcomponents and the mating fastening components tend to form a butt jointthat minimizes overlap of the front and back waist regions and furtherenhances the garment-like appearance of the absorbent article. Thispositioning of the fastening components also causes the refastenableseams to become more flush with the primary absorbent structure of theabsorbent article.

In another embodiment, the present invention pertains to an absorbentarticle including a generally inelastic absorbent chassis comprising abodyside liner, an outer cover bonded to the bodyside liner, and anabsorbent assembly disposed between the bodyside liner and the outercover. The absorbent chassis defines a longitudinal axis, a transverseaxis, front and back waist edges parallel to the transverse axis,opposite side edges extending between the front and back waist edges, afront waist region contiguous with the front waist edge, a back waistregion contiguous with the back waist edge, and a crotch region whichextends between and interconnects the front and back waist regions.First and second elastomeric side panels extend transversely outwardfrom the absorbent assembly in the back waist region. The absorbentarticle also includes a fastening system for releasably securing theabsorbent article in a pant-like configuration. The fastening systemincludes first and second fastening components adapted to releasablyengage first and second mating fastening components. The fasteningcomponents are disposed on the elastomeric side panels and having alength dimension, a width dimension, and a length-to-width ratio ofabout 2 or greater. The mating fastening components are disposed on thegenerally inelastic absorbent chassis in the front waist region andpositioned along the opposite side edges abutting the front waist edge.

This embodiment of the invention provides an absorbent article withefficient utilization of elastomeric materials to obtain proper fit onthe wearer. The absorbent article can be formed with a generallyinelastic absorbent chassis, which as that term is used herein, refersto the combined structure of a bodyside liner, an outer cover and anabsorbent assembly where neither the bodyside liner nor the outer coveris formed with a unitary elastomeric material. In particular, legelastic members and waist elastic members may be operatively joined tothe combined structure, but the bodyside liner and outer cover materialsthemselves are not elastomeric. The inelastic absorbent chassisdesirably concentrates the elastic forces over the hips and around theback side of the wearer. Concentration of elastic forces in these areasis more efficient for holding the product up on the wearer than isconcentration of elastic forces across the front waist region. Theinelastic absorbent chassis also avoids the difficulties in mounting anon-stretchable absorbent in an elastic chassis. Inelastic liners andouter covers can be more suitable for containing the absorbentstructure, in that they help prevent uncomfortable bunching andmigration of absorbent material through the liner and onto the skin.

In another embodiment, the present invention pertains to an absorbentarticle including a generally inelastic absorbent chassis and afastening system for releasably attaching a front waist region of theabsorbent chassis to a back waist region of the absorbent chassis todefine a refastenable pant. The refastenable pant has a waist openingand a pair of leg openings and includes: a pair of refastenable seamsextending from the waist opening to each leg opening; a pair ofelastomeric side panels extending from the waist opening to each legopening; an elastomeric front waistband disposed in the front waistregion and positioned between the pair of refastenable seams; anelastomeric back waistband disposed in the back waist region andpositioned between the pair of elastomeric side panels; and a pair ofelastomeric leg members which partially encircle each leg opening, whereeach elastomeric leg member extends from adjacent a refastenable seam inthe front waist region to adjacent an elastomeric side panel in the backwaist region.

This embodiment of the invention provides an absorbent article thatprovides fit and comfort comparable to conventional training pants, yetprovides the added benefits of refastenability. The elastomeric sidepanels generally span the hips of the wearer and provide elasticity fromthe waist opening to each leg opening. The absorbent article fitsclosely about the body of the wearer due to the combination of theelastomeric side panels, the elastomeric front waistband, theelastomeric back waistband, and the elastomeric leg members, without theneed for an elastomeric absorbent chassis. The absorbent article issecurely held in place with a garment-like seam due to the refastenableseams extending from the waist opening to each leg opening.

The refastenable seams are formed when the first and second fasteningcomponents are engaged with the first and second mating fasteningcomponents. The refastenable seams are desirably relatively thin, narrowand flexible to afford the look and feel of a cloth garment. Thus, inparticular embodiments, the refastenable seams have a length-to-widthratio of about 2 or greater, such as about 2 to about 25, particularlyabout 5 or greater, such as about 5 to about 8. The refastenable seamsdefine a length dimension and a width dimension that is perpendicular tothe length dimension. For a child of about 9 to about 15 kilograms(20-34 lbs.), for example, the length dimension is desirably from about5 to about 13 centimeters, such as about 10 centimeters, and the widthdimension is desirably from about 0.5 to about 3 centimeters, such asabout 2 centimeters. Desirably although not necessarily, the lengthdimension is aligned generally parallel to the longitudinal axis of theabsorbent article and the width dimension is aligned generally parallelto the transverse axis of the absorbent article. The term “generallyparallel” as used herein refers to an angle within about 35 degrees orless of the referenced axis, and more particularly within about 20degrees or less of the referenced axis.

The fastening components may comprise any refastenable fastenerssuitable for absorbent articles, such as mechanical fastening elementsor adhesive fastening elements. Suitable mechanical fastening elementscan be provided by interlocking geometric shaped materials, such ashooks, loops, bulbs, mushrooms, arrowheads, balls on stems, male andfemale mating components, buckles, snaps, or the like. In particularembodiments, the fastening components and mating fastening componentscomprise hook-and-loop-fastening elements. One skilled in the art willrecognize that the shape, density and polymer composition of the hooksand loops may be selected to obtain the desired level of securementbetween the fastening components and the mating fastening components. Amore aggressive hook material may comprise a material with a greateraverage hook height, a greater percentage of directionally-alignedhooks, or a more aggressive hook shape.

As disclosed in copending U.S. Patent Application Ser. No. 60/112,709,filed on Dec. 18, 1998 by C. P. Olson et al. and titled “AbsorbentArticles Having Differential Strength Refastenable Seam,” therefastenable seam can include one or more main refastenable attachmentzones and one or more enhanced refastenable attachment zones. The mainand enhanced refastenable attachment zones may be constructed to providedifferential levels of securement, and particularly augmented levels ofsecurement at locations which are subject to greater levels ofseparation forces.

As disclosed in copending U.S. Patent Application Ser. No. 60/112,775,filed on Dec. 18, 1998 by C. P. Olson and titled “Absorbent ArticlesHaving Hinged Fasteners,” the refastenable seam may comprise individualfastening materials with narrow spacings therebetween. The narrowspacings provide a desirable hinge to improve fit and securement of thefastening components.

The disclosed absorbent articles are adapted to be worn adjacent to thebody of a wearer to absorb and contain various exudates discharged fromthe body. The absorbent articles are desirably pre-fastened to provide apant-like product for the user. The product can then be pulled on like aconventional training pant, and subsequently checked or removed with theease of a diaper-like product. Moreover, the product may be applied likea diaper rather than like a pant. Supplemental releasable fasteningmeans such as frangible point bonds may be employed to maintain theabsorbent article in a pant configuration until the user intentionallydisengages the fasteners.

The fastening system allows for easy inspection of the interior of thepant-like product. If necessary, the fastening system also allows thepant to be removed quickly and easily. This is particularly beneficialwhen the pant contains messy excrement. If desired, the caregiver cancompletely remove the pant-like product and replace it with a new onewithout having to remove the child's shoes and clothing. The presentfastening system may be used with a wide variety of absorbent products,including training pants, diapers, incontinence garments, or othergarments using mechanical or adhesive fasteners.

The present invention also pertains to a method of making an absorbentarticle. In one embodiment, a method of making an absorbent articlecomprises: providing an absorbent chassis defining a longitudinal axis,a transverse axis, front and back waist edges parallel to the transverseaxis, opposite side edges extending between the front and back waistedges, a front waist region contiguous with the front waist edge, a backwaist region contiguous with the back waist edge, and a crotch regionwhich extends between and interconnects the front and back waistregions, the absorbent chassis comprising a rectangular compositestructure having linear side edges parallel to the longitudinal axis andopposite linear end edges parallel to the transverse axis, the compositestructure comprising a bodyside liner, an outer cover bonded to thebodyside liner, and an absorbent assembly disposed between the bodysideliner and the outer cover; bonding a pair of elastomeric side panels tothe rectangular composite structure in the back waist region, the sidepanels being elastomeric in a direction parallel to the transverse axis;bonding first and second fastening components to the elastomeric sidepanels, each of the fastening components having a length dimension, awidth dimension, and a length-to-width ratio of about 2 or greater; andbonding first and second mating fastening components to the absorbentchassis in the front waist region along the opposite side edges abuttingthe front waist edge, the fastening components adapted to releasablyengage the mating fastening components.

A more detailed description of the construction and design of one formof training pant can be found in U.S. Pat. No. 4,940,464 issued Jul. 10,1990 to Van Gompel et al., which is incorporated herein by reference.The Van Gompel et al. patent describes various materials of which thetraining pant can be made, and a method of constructing a training pant.

DEFINITIONS

Within the context of this specification, each term or phrase below willinclude the following meaning or meanings.

“Bonded” refers to the joining, adhering, connecting, attaching, or thelike, of two elements. Two elements will be considered to be bondedtogether when they are bonded directly to one another or indirectly toone another, such as when each is directly bonded to intermediateelements.

“Comprising” is inclusive or open-ended and does not exclude additional,unrecited elements or method steps.

“Connected” refers to the joining, adhering, bonding, attaching, or thelike, of two elements. Two elements will be considered to be connectedtogether when they are connected directly to one another or indirectlyto one another, such as when each is directly connected to intermediateelements.

“Disposable” refers to articles which are designed to be discarded aftera limited use rather than being laundered or otherwise restored forreuse.

“Disposed,” “disposed on,” and variations thereof are intended to meanthat one element can be integral with another element, or that oneelement can be a separate structure bonded to or placed with or placednear another element.

“Elastic,” “elasticized” and “elasticity” mean that property of amaterial or composite by virtue of which it tends to recover itsoriginal size and shape after removal of a force causing a deformation.

“Elastomeric” refers to a material or composite which can be elongatedby at least 25 percent of its relaxed length and which will recover,upon release of the applied force, is at least 10 percent of itselongation. It is generally preferred that the elastomeric material orcomposite be capable of being elongated by at least 100 percent, morepreferably by at least 300 percent, of its relaxed length and recover,upon release of an applied force, at least 50 percent of its elongation.

“Fabrics” is used to refer to all of the woven, knitted and nonwovenfibrous webs.

“Flexible” refers to materials which are compliant and which willreadily conform to the general shape and contours of the wearer's body.

“Force” includes a physical influence exerted by one body on anotherwhich produces acceleration of bodies that are free to move anddeformation of bodies that are not free to move. Force is expressed ingrams per unit area.

“Graphic” refers to any design, pattern, or the like that is visible onan absorbent article.

“Hydrophilic” describes fibers or the surfaces of fibers which arewetted by the aqueous liquids in contact with the fibers. The degree ofwetting of the materials can, in turn, be described in terms of thecontact angles and the surface tensions of the liquids and materialsinvolved. Equipment and techniques suitable for measuring thewettability of particular fiber materials or blends of fiber materialscan be provided by a Cahn SFA-222 Surface Force Analyzer System, or asubstantially equivalent system. When measured with this system, fibershaving contact angles less than 90° are designated “wettable” orhydrophilic, while fibers having contact angles greater than 90° aredesignated “nonwettable” or hydrophobic.

“Integral” is used to refer to various portions of a single unitaryelement rather than separate structures bonded to or placed with orplaced near one another.

“Inward” and “outward” refer to positions relative to the center of anabsorbent article and particularly transversely and/or longitudinallycloser to or away from the longitudinal and transverse center of theabsorbent article.

“Layer” when used in the singular can have the dual meaning of a singleelement or a plurality of elements.

“Liquid impermeable”, when used in describing a layer or multi-layerlaminate, means that a liquid, such as urine, will not pass through thelayer or laminate, under ordinary use conditions, in a directiongenerally perpendicular to the plane of the layer or laminate at thepoint of liquid contact. Liquid, or urine, may spread or be transportedparallel to the plane of the liquid impermeable layer or laminate, butthis is not considered to be within the meaning of “liquid impermeable”when used herein.

“Longitudinal” and “transverse” have their customary meaning, asindicated by the longitudinal and transverse axes depicted in FIGS. 2and 3. The longitudinal axis lies in the plane of the article and isgenerally parallel to a vertical plane that bisects a standing wearerinto left and right body halves when the article is worn. The transverseaxis lies in the plane of the article generally perpendicular to thelongitudinal axis. The article as illustrated is longer in thelongitudinal direction than in the transverse direction.

“Member” when used in the singular can have the dual meaning of a singleelement or a plurality of elements.

“Nonwoven web” means a web of material which is formed without the aidof a textile weaving or knitting process.

“Operatively joined,” with reference to the attachment of an elasticmember to another element, means that the elastic member when attachedto or connected to the element, or treated with heat or chemicals, bystretching, or the like, gives the element elastic properties; and withreference to the attachment of a non-elastic member to another element,means that the member and element can be attached in any suitable mannerthat permits or allows them to perform the intended or describedfunction of the joinder. The joining, attaching, connecting or the likecan be either directly, such as joining either member directly to anelement, or can be indirectly by means of another member disposedbetween the first member and the first element.

“Outer cover graphic” refers to a graphic that is directly visible uponinspection of the exterior surface of a garment, and for a refastenablegarment is in reference to inspection of the exterior surface of thegarment when the fastening system is engaged as it would be during use.

“Permanently bonded” refers to the joining, adhering, connecting,attaching, or the like, of two Elements of an absorbent garment suchthat the elements tend to be and remain bonded during normal useconditions of the absorbent garment.

“Refastenable” refers to the property of two elements being capable ofreleasable attachment, separation, and subsequent releasablereattachment without substantial permanent deformation or rupture.

“Releasably attached,” “releasably connected,” “releasably engaged” andvariations thereof refer to two elements being connected or connectablesuch that the elements tend to remain connected absent a separationforce applied to one or both of the elements, and the elements beingcapable of separation without substantial permanent deformation orrupture. The required separation force is typically beyond thatencountered while wearing the absorbent garment.

“Rupture” means the breaking or tearing apart of a material; in tensiletesting, the term refers to the total separation of a material into twoparts either all at once or in stages, or the development of a hole insome materials.

“Stretch bonded” refers to an elastic member being bonded to anothermember while the elastic member is extended at least about 25 percent ofits relaxed length. Desirably, the term “stretch bonded” refers to thesituation wherein the elastic member is extended at least about 100percent and more desirably at least about 300 percent, of its relaxedlength when it is bonded to the other member.

“Stretch bonded laminate” refers to a composite material having at leasttwo layers in which one layer is a gatherable layer and the other layeris an elastic layer. The layers are joined together when the elasticlayer is in an extended condition so that upon relaxing the layers, thegatherable layer is gathered.

“Surface” includes any layer, film, woven, nonwoven, laminate,composite, or the like, whether pervious or impervious to air, gas,and/or liquids.

“Tension” includes a uniaxial force tending to cause the extension of abody or the balancing force within that body resisting the extension.

“Thermoplastic” describes a material that softens when exposed to heatand which substantially returns to a nonsoftened condition when cooledto room temperature.

These terms may be defined with additional language in the remainingportions of the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features of the present invention and themanner of attaining them will become more apparent, and the inventionitself will be better understood by reference to the followingdescription and the accompanying drawings, wherein similar features indifferent figures have been given the same reference numeral.

FIG. 1 illustrates a front perspective view of one type of disposableabsorbent article incorporating the principles of the present invention,where the fastening system is shown engaged on one side of the absorbentarticle and disengaged on the other side of the absorbent article.

FIG. 2 illustrates a plan view of the disposable absorbent article shownin FIG. 1 in an unfastened, stretched and laid flat condition, andshowing the surface of the article that faces away from the wearer, withportions cut away to show the underlying features.

FIG. 3 illustrates a plan view similar to FIG. 2, but showing thesurface of the article that faces the wearer when the article is worn,and with portions cut away to show the underlying features.

FIG. 4 illustrates a plan view of a side panel of an alternativedisposable absorbent article incorporating the principles of the presentinvention, in an unfastened, stretched and laid flat condition andshowing the surface of the article that faces the wearer when thearticle is worn.

FIG. 5 illustrates a plan view of an alternative disposable absorbentarticle shown in an unfastened, stretched and laid flat condition, andshowing the surface of the article that faces away from the wearer.

FIG. 6 illustrates an enlarged sectional view of a portion of anattachment panel of the absorbent article shown in FIG. 5.

FIG. 7 illustrates an enlarged plan view of a back side panel of thetype shown in FIG. 5.

FIG. 8 illustrates an enlarged plan view of a front side panel of thetype shown in FIG. 5.

DETAILED DESCRIPTION OF THE DRAWINGS

The principles of the present invention can be incorporated into anysuitable disposable absorbent article and its method of manufacture.Examples of such suitable articles include diapers, training pants,feminine hygiene products, incontinence products, other personal care orhealth care garments, or the like. For ease of explanation, thedescription hereafter will be in terms of a child's training pant.

With reference to FIG. 1, a disposable absorbent article, such as atraining pant 20, is illustrated in a partially fastened condition. Thetraining pant 20 comprises an absorbent chassis 32 and a fasteningsystem 80. The absorbent chassis 32 defines a front waist region 22, aback waist region 24, a crotch region 26 interconnecting the front andback waist regions, an inner surface 28 which is configured to contactthe wearer, and an outer surface 30 opposite the inner surface which isconfigured to contact the wearer's clothing. With additional referenceto FIGS. 2 and 3, the absorbent chassis 32 also defines a pair oftransversely opposed side edges 36 and a pair of longitudinally opposedwaist edges, which are designated front waist edge 38 and back waistedge 39. The front waist region 22 is contiguous with the front waistedge 38, and the back waist region 24 is contiguous with the back waistedge 39.

The illustrated absorbent chassis 32 comprises a rectangular compositestructure 33 and a pair of transversely opposed side panels 34. Thecomposite structure 33 and side panels 34 may be integrally formed orcomprise two or more separate elements, as shown in FIG. 1. Theillustrated composite structure 33 comprises an outer cover 40, abodyside liner 42 which is connected to the outer cover in a superposedrelation, an absorbent assembly 44 (FIGS. 2 and 3) which is locatedbetween the outer cover and the bodyside liner, and a pair ofcontainment flaps 46 (FIGS. 1 and 3). The rectangular compositestructure 33 has opposite linear end edges 45 that form portions of thefront and back waist edges 38 and 39, and opposite linear side edges 47that form portions of the side edges 36 of the absorbent chassis 32(FIGS. 2 and 3). For reference, arrows 48 and 49 depicting theorientation of the longitudinal axis and the transverse axis,respectively, of the training pant 20 are illustrated in FIGS. 2 and 3.

With the training pant 20 in the fastened position as partiallyillustrated in FIG. 1, the front and back waist regions 22 and 24 arejoined together to define a three dimensional pant configuration havinga waist opening 50 and a pair of leg openings 52. The front waist region22 comprises the portion of the training pant 20 which, when worn, ispositioned on the front of the wearer while the back waist region 24comprises the portion of the training pant which, when worn, ispositioned on the back of the wearer. The crotch region 26 of thetraining pant 20 comprises the portion of the training pant which, whenworn, is positioned between the legs of the wearer and covers the lowertorso of the wearer. The side panels 34 comprise the portions of thetraining pant 20 which, when worn, are positioned on the side hipregions of the wearer. The back waist region 24 of the absorbent chassis32 includes the transversely opposed side panels 34 and a center panel35 (FIGS. 2 and 3) positioned between and connecting the side panels.

The waist edges 38 and 39 of the absorbent chassis 32 and the sidepanels 34 are configured to encircle the waist of the wearer when wornand provide the waist opening 50 which defines a waist perimeterdimension. Portions of the transversely opposed side edges 36 of theabsorbent chassis 32 and the side panels 34 generally define the legopenings 52.

The absorbent chassis 32 is configured to contain and/or absorb any bodyexudates discharged from the wearer. For example, the absorbent chassis32 desirably although not necessarily comprises the pair of containmentflaps 46 which are configured to provide a barrier to the transverseflow of body exudates. A flap elastic member 53 (FIG. 3) is operativelyjoined with each containment flap 46 in any suitable manner as is wellknown in the art. The elasticized containment flaps 46 define anunattached edge which assumes an upright, generally perpendicularconfiguration in at least the crotch region 26 of the training pant 20to form a seal against the wearer's body. The containment flaps 46 canbe located along the transversely opposed side edges of the absorbentchassis 32, and can extend longitudinally along the entire length of theabsorbent chassis or may only extend partially along the length of theabsorbent chassis. Suitable constructions and arrangements for thecontainment flaps 46 are generally well known to those skilled in theart and are described in U.S. Pat. No. 4,704,116 issued Nov. 3, 1987 toEnloe, which is incorporated herein by reference.

To further enhance containment and/or absorption of body exudates, thetraining pant 20 desirably includes a front waist elastic member 54, arear waist elastic member 56, and leg elastic members 58, as are knownto those skilled in the art (FIG. 3). The waist elastic members 54 and56 can be operatively joined to the outer cover 40 and/or bodyside liner42 along the opposite waist edges 38 and 39, and can extend over part orall of the waist edges.

The leg elastic members 58 are desirably operatively joined to the outercover 40 and/or bodyside liner 42 along the opposite side edges 36 andpositioned in the crotch region 26 of the training pant 20. The legelastic members 58 are desirably longitudinally aligned along each sideedge 47 of the composite structure 33. Each leg elastic member 58 has afront terminal point 63 and a back terminal point 65, which pointsrepresent the longitudinal ends of the elastic gathering caused by theleg elastic members.

The flap elastic members 53, the waist elastics 54 and 56, and the legelastics 58 can be formed of any suitable elastic material. As is wellknown to those skilled in the art, suitable elastic materials includesheets, strands or ribbons of natural rubber, synthetic rubber, orthermoplastic elastomeric polymers. The elastic materials can bestretched and adhered to a substrate, adhered to a gathered substrate,or adhered to a substrate and then elasticized or shrunk, for examplewith the application of heat; such that elastic constrictive forces areimparted to the substrate. In one particular embodiment, for example,the leg elastic members 58 comprise a plurality of dry-spun coalescedmultifilament spandex elastomeric threads sold under the trade nameLYCRA® and available from E. I. Du Pont de Nemours and Company,Wilmington, Del., U.S.A.

The outer cover 40 desirably comprises a material that is substantiallyliquid impermeable. The outer cover 40 can be a single layer of liquidimpermeable material, but desirably comprises a multi-layered laminatestructure in which at least one of the layers is liquid impermeable. Forinstance, the outer cover 40 can include a liquid permeable outer layerand a liquid impermeable inner layer that are suitably joined togetherby a laminate adhesive (not shown). Suitable laminate adhesives, whichcan be applied continuously or intermittently as beads, a spray,parallel swirls, or the like, can be obtained from Findley Adhesives,Inc., of Wauwatosa, Wis., U.S.A., or from National Starch and ChemicalCompany, Bridgewater, N.J., U.S.A. The liquid permeable outer layer canbe any suitable material and desirably one that provides a generallycloth-like texture. One example of such a material is a 20 gsm (gramsper square meter) spunbond polypropylene nonwoven web. The outer layermay also be made of those materials of which liquid permeable bodysideliner 42 is made. While it is not a necessity for outer layer to beliquid permeable, it is desired that it provides a relatively cloth-likeis texture to the wearer.

The inner layer of the outer cover 40 can be both liquid and vaporimpermeable, or can be liquid impermeable and vapor permeable. The innerlayer is desirably manufactured from a thin plastic film, although otherflexible liquid impermeable materials may also be used. The inner layer,or the liquid impermeable outer cover 40 when a single layer, preventswaste material from wetting articles, such as bedsheets and clothing, aswell as the wearer and caregiver. A suitable liquid impermeable film foruse as liquid impermeable inner layer, or a single layer liquidimpermeable outer cover 40, is a 1.0 mil polyethylene film commerciallyavailable from Edison Plastics Company of South Plainfield, N.J., U.S.A.If the outer cover 40 is a single layer of material, it can be embossedand/or matte finished to provide a more cloth-like appearance. Asearlier mentioned, the liquid impermeable material can permit vapors toescape from the interior of the disposable absorbent article, whilestill preventing liquids from passing through the outer cover 40. Asuitable “breathable” material is composed of a microporous polymer filmor a nonwoven fabric that has been coated or otherwise treated to imparta desired level of liquid impermeability. A suitable microporous film isa PMP-1 film material commercially available from Mitsui ToatsuChemicals, Inc., Tokyo, Japan, or an XKO-8044 polyolefin filmcommercially available from 3M Company, Minneapolis, Minn., U.S.A.

As shown in FIGS. 1 and 2, the training pant 20 and in particular theouter cover 40 desirably comprises one or more appearance-relatedcomponents. Examples of appearance-related components include, but arenot limited to, graphics; highlighting or emphasizing leg and waistopenings in order to make product shaping more evident or visible to theuser; highlighting or emphasizing areas of the product to simulatefunctional components such as elastic leg bands, elastic waistbands,simulated “fly openings” for boys, ruffles for girls; highlighting areasof the product to change the appearance of the size of the product;registering wetness indicators, temperature indicators, and the like inthe product; registering a back label, or a front label, in the product;and registering written instructions at a desired location in theproduct.

The illustrated training pant 20, which is designed for use by younggirls, includes a registered outer cover graphic 60. In this design, theouter cover graphic 60 includes a rainbow, sun, clouds, wagon andballoon. Again, any suitable design can be utilized for a training pantintended for use by young girls, so as to be aesthetically and/orfunctionally pleasing to them and the caregiver. The appearance-relatedcomponents are desirably positioned on the training pant 20 at selectedlocations, which can be carried out using the methods disclosed in U.S.Pat. No. 5,766,389 issued Jun. 16, 1998 to Brandon et al., which isincorporated herein by reference.

The liquid permeable bodyside liner 42 is illustrated as overlying theouter cover 40 and absorbent assembly 44, and may but need not have thesame dimensions as the outer cover 40. The bodyside liner 42 isdesirably compliant, soft feeling, and non-irritating to the child'sskin. Further, the bodyside liner 42 can be less hydrophilic than theabsorbent assembly 44, to present a relatively dry surface to the wearerand permit liquid to readily penetrate through its thickness.

The bodyside liner 42 can be manufactured from a wide selection of webmaterials, such as synthetic fibers (for example, polyester orpolypropylene fibers), natural fibers (for example, wood or cottonfibers), a combination of natural and synthetic fibers, porous foams,reticulated foams, apertured plastic films, or the like. Various wovenand nonwoven fabrics can be used for the bodyside liner 42. For example,the bodyside liner can be composed of a meltblown or spunbonded web ofpolyolefin fibers. The bodyside liner can also be a bonded-carded webcomposed of natural and/or synthetic fibers. The bodyside liner can becomposed of a substantially hydrophobic material, and the hydrophobicmaterial can, optionally, be treated with a surfactant or otherwiseprocessed to impart a desired level of wettability and hydrophilicity.For example, the material can be surface treated with about 0.28 weightpercent of a surfactant commercially available from the Rohm and HaasCo. under the trade designation Triton X-102. The surfactant can beapplied by any conventional means, such as spraying, printing, brushcoating or the like. The surfactant can be applied to the entirebodyside liner 42 or can be selectively applied to particular sectionsof the bodyside liner, such as the medial section along the longitudinalcenterline.

A suitable liquid permeable bodyside liner 42 is a nonwoven bicomponentweb having a basis weight of about 27 gsm. The nonwoven bicomponent canbe a spunbond bicomponent web, or a bonded carded bicomponent web.Suitable bicomponent staple fibers include a polyethylene/polypropylenebicomponent fiber available from CHISSO Corporation, Osaka, Japan. Inthis particular bicomponent fiber, the polypropylene forms the core andthe polyethylene forms the sheath of the fiber. Other fiber orientationsare possible, such as multi-lobe, side-by-side, end-to-end, or the like.While the outer cover 40 and bodyside liner 42 can comprise elastomericmaterials, it is particularly desirable in some embodiments describedherein for the outer cover and bodyside liner to comprise materials thatare generally not elastomeric.

The absorbent assembly 44 (FIG. 3) is positioned between the outer cover40 and the bodyside liner 42, which components can be joined together byany suitable means such as adhesives as is well known in the art. Theabsorbent assembly 44 can be any structure which is generallycompressible, conformable, non-irritating to the child's skin, andcapable of absorbing and retaining liquids and certain body wastes. Theabsorbent assembly 44 can be manufactured in a wide variety of sizes andshapes, and from a wide variety of liquid absorbent materials commonlyused in the art. For example, the absorbent assembly 44 can suitablycomprise a matrix of hydrophilic fibers, such as a web of cellulosicfluff, mixed with particles of a high-absorbency material commonly knownas superabsorbent material. In a particular embodiment, the absorbentassembly 44 comprises a matrix of cellulosic fluff, such as wood pulpfluff, and superabsorbent hydrogel-forming particles. The wood pulpfluff can be exchanged with synthetic, polymeric, meltblown fibers orwith a combination of meltblown fibers and natural fibers. Thesuperabsorbent particles may be substantially homogeneously mixed withthe hydrophilic fibers or may be nonuniformly mixed. The fluff andsuperabsorbent particles can also be selectively placed into desiredzones of the absorbent assembly 44 to better contain and absorb bodyexudates. The concentration of the superabsorbent particles can alsovary through the thickness of the absorbent assembly 44. Alternatively,the absorbent assembly 44 can comprise a laminate of fibrous webs andsuperabsorbent material or other suitable means of maintaining asuperabsorbent material in a localized area.

Suitable superabsorbent materials can be selected from natural,synthetic, and modified natural polymers and materials. Thesuperabsorbent materials can be inorganic materials, such as silicagels, or organic compounds, such as crosslinked polymers. Suitablesuperabsorbent materials are available from various commercial vendors,such as Dow Chemical Company located in Midland, Mich., U.S.A., andStockhausen GmbH & Co. KG, 0-47805 Krefeld, Federal Republic of Germany.Typically, a superabsorbent material is capable of absorbing at leastabout 15 times its weight in Water, and desirably is capable ofabsorbing more than about 25 times its weight in water.

In one embodiment, the absorbent assembly 44 is generally rectangular inshape, and comprises a blend of wood pulp fluff and superabsorbentmaterial. One preferred type of fluff is identified with the tradedesignation CR1654, available from Kimberly-Clark Corporation, Neenah,Wis., U.S.A., and is a bleached, highly absorbent sulfate wood pulpcontaining primarily soft wood fibers. As a general rule, thesuperabsorbent material is present in the absorbent assembly 44 in anamount of from about 5 to about 90 weight percent based on total weightof the absorbent assembly. The absorbent assembly 44 suitably has adensity within the range of about 0.10 to about 0.35 grams per cubiccentimeter. The absorbent assembly 44 may or may not be wrapped orencompassed by a suitable tissue wrap that maintains the integrityand/or shape of absorbent assembly.

The absorbent chassis 32 can also incorporate other materials that aredesigned primarily to receive, temporarily store, and/or transportliquid along the mutually facing surface with absorbent assembly 44,thereby maximizing the absorbent capacity of absorbent assembly. Onesuitable material is referred to as a surge layer (not shown) andcomprises a material having a basis weight of about 50 grams per squaremeter, and comprising a through-air-bonded-carded web of a homogenousblend of 60 percent 3 denier bicomponent fiber comprising a polyestercore/polyethylene sheath, commercially available from BASF Corporation,and 40 percent 6 denier polyester fiber, commercially available fromHoechst Celanese Corporation located in Portsmouth, Va. U.S.A.

For purposes of the present invention, the absorbent assembly 44 isconsidered to have an absorbent batt 75 that represents the primaryabsorbent structure of the absorbent assembly. The absorbent batt 75includes opposite side edges 76 that are generally longitudinallyoriented within the absorbent chassis 32 (FIGS. 2 and 3).

As noted previously, the illustrated training pant 20 has a side panel34 disposed on each side of the absorbent chassis 32. The pair oftransversely opposed side panels 34 are permanently bonded to thecomposite structure 33 of the absorbent chassis 32 in at least one ofthe waist regions 22 and 24 and releasably attached to the absorbentchassis in the opposite waist region. For example, as shown best inFIGS. 2 and 3, the side panels 34 are permanently bonded to and extendtransversely beyond the side edges 47 of the composite structure 33 inthe back waist region 24 along an attachment line 66.

The illustrated side panels 34 define a distal edge 68 that is spacedfrom the attachment line 66, a leg end edge 70, and a waist end edge 72.The leg end edge 70 and waist end edge 72 extend from the side edges 47of the composite structure 33 to the distal edges 68. The leg end edges70 of the side panels 34 form part of the side edges 36 of the absorbentchassis 32 and are desirably although not necessarily angled relative tothe transverse axis 49 to provide greater coverage toward the back ofthe pant as compared to the front of the pant. The waist end edges 72are desirably parallel to the transverse axis 49 and form part of theback waist edge 39 of the absorbent chassis 32. Further, the waist endedges 72 are desirably substantially aligned with the linear end edges45 of the composite structure 33, and particularly longitudinally offsetby about 1 centimeter or less.

In particular embodiments for improved fit and appearance, the sidepanels 34 desirably have an average length dimension measured parallelto the longitudinal axis 48 that is about 20 percent or greater, andparticularly about 25 percent or greater, of the overall lengthdimension of the absorbent article, also measured parallel to thelongitudinal axis 48. For example, in training pants having an overalllength dimension of about 54 centimeters, the side panels 34 desirablyhave an average length dimension of about 10 centimeters or greater,such as about 15 centimeters. As illustrated the side panels 34 extendfrom the waist opening 50 to one of the leg openings 52 and have acontinually decreasing length dimension moving from the attachment line66 to the distal edge 68.

The side panels 34 are permanently bonded to the composite structure 33along the attachment line 66 using attachment means known to thoseskilled in the art such as adhesive, thermal or ultrasonic bonding. Insuch a configuration, each of the side panels 34 can be releasablyattached to the absorbent chassis 32 in the front waist region 22 of thetraining pant 20 as will be discussed hereinafter in more detail.Alternatively, the side panels 34 may be permanently bonded to the sideedges 47 in the front waist region 22 and releasably attached to theside edges 36 in the back waist region 24 if it is desired that thefasteners be located towards the back of the wearer. Such aconfiguration may be desirable to prevent a wearer from unfastening thearticle prematurely.

Each of the side panels 34 can include one or more individual, distinctpieces of material. In particular embodiments, for example, each sidepanel 34 can include front and back side panel portions that are joinedat a seam (see FIG. 4). Still alternatively, each individual side panel34 can include a single piece of material which is folded over uponitself along an intermediate fold line (not shown).

The side panels 34 desirably comprise an elastic material capable ofstretching in a direction parallel to the transverse axis 49 of thetraining pant 20. In particular embodiments, each side panel 34 maycomprise an interior portion 78 disposed between the distal edge 68 andthe center panel 35 of the back waist region 24. In the illustratedembodiment, the interior portion 78 is disposed between the distal edge68 and the side edges 47 of the rectangular composite structure 33. Theelastic material of the side panels 34 can be disposed in the interiorportions 78 to render the side panels elastomeric in a directionparallel to the transverse axis 49. Most desirably, each side panel 34is elastomeric from the waist end edge 72 to the leg end edge 70. Morespecifically, individual samples of side panel material, taken betweenthe waist end edge 72 and the leg end edge 70 parallel to the transverseaxis 49 and having a length from the attachment line 66 to the distaledge 68 and a width of 2 centimeters, are all elastomeric.

Suitable elastic materials, as well as one described process ofincorporating elastic side panels into a training pant, are described inthe following U.S. Pat. Nos. 4,940,464 issued Jul. 10, 1990 to VanGompel et al.; 5,224,405 issued Jul. 6, 1993 to Pohjola; 5,104,116issued Apr. 14, 1992 to Pohjola; and 5,046,272 issued Sep. 10, 1991 toVogt et al.; all of which are incorporated herein by reference. Inparticular embodiments, the elastic material comprises a stretch-thermallaminate (STL), a neck-bonded laminate (NBL), a reversibly neckedlaminate, or a stretch-bonded laminate (SBL) material. Methods of makingsuch materials are well known to those skilled in the art and describedin U.S. Pat. No. 4,663,220 issued May 5, 1987 to Wisneski et al.; U.S.Pat. No. 5,226,992 issued Jul. 13, 1993 to Mormon; and European PatentApplication No. EP 0 217 032 published on Apr. 8, 1987 in the names ofTaylor et al.; all of which are incorporated herein by reference.Alternatively, the side panel material may comprise other woven ornonwoven materials, such as those described above as being suitable forthe outer cover 40 or bodyside liner 42.

The training pant 20 according to the present invention also includes afastening system 80 for securing the training pant about the waist ofthe wearer (FIGS. 2 and 3). The illustrated fastening system 80 includesfirst and second fastening components 82 and 83 that are adapted torefastenably connect to first and second mating fastening components 84and 85. In one embodiment, one surface of each of the first and secondfastening components 82 and 83 comprises a plurality of engagingelements that project from that surface. The engaging elements of thesefastening components 82 and 83 are adapted to repeatedly engage anddisengage the engaging elements of the mating fastening components 84and 85.

In one particular embodiment, the first and second fastening components82 and 83 each comprise hook type fasteners and the first and secondmating fastening components 84 and 85 each comprise complimentary looptype fasteners. In another particular embodiment, the first and secondfastening components 82 and 83 each comprise loop type fasteners and thefirst and second mating fastening components 84 and 85 each comprisecomplimentary hook type fasteners. Loop type fasteners typicallycomprise a fabric or material having a base or backing structure and aplurality of loop members extending upwardly from at least one surfaceof the backing structure. The loop material can be formed of anysuitable material, such as acrylic, nylon or polyester, and can beformed by methods such as warp knitting, stitch bonding or needlepunching. Suitable loop materials are available from Guilford Mills,Inc., Greensboro, N.C., U.S.A. under the trade designation No. 36549.

Hook type fasteners typically comprise a fabric or material having abase or backing structure and a plurality of hook members extendingupwardly from at least one surface of the backing structure. In contrastto the loop type fasteners which desirably comprise a flexible fabric,the hook material advantageously comprises a resilient material tominimize unintentional disengagement of the fastener components as aresult of the hook material becoming deformed and catching on clothingor other items. The term “resilient” as used herein refers to aninterlocking material having a predetermined shape and the property ofthe interlocking material to resume the predetermined shape after beingengaged and disengaged from a mating, complementary interlockingmaterial. Suitable hook material can be molded or extruded of nylon,polypropylene or another suitable material. Suitable single-sided hookmaterials for the fastening components 82 and 83 or the mating fasteningcomponents 84 and 85 are available from Velcro Industries B.V.,Amsterdam, Netherlands or affiliates thereof, and are identified asVelcro HTH-829 with a uni-directional hook pattern and having athickness of about 0.089 millimeters (3.5 mils) and HTH-851 with auni-directional hook pattern and having a thickness of about 0.051millimeters (2 mils).

With reference to FIG. 3, the first and second fastening components 82and 83 are desirably located on the inner surface 28 of the trainingpant 20 in the back waist region 24. The first and second fasteningcomponents 82 and 83 are desirably positioned along the distal edge 68of the side panels 34. The first and second fastening components 82 and83 can be adhered to the side panels 34 by any means known to thoseskilled in the art such as adhesive bonds, sonic bonds or thermal bonds.

With reference to FIG. 2, the first and second mating fasteningcomponents 84 and 85 can be located on the outer surface 30 of thetraining pant 20 in the front waist region 22. The first and secondmating fastening components 84 and 85 are sized to receive the first andsecond fastening components 82 and 83 and are desirably positioned alongthe side edges 36 of the absorbent chassis 32, and in particular alongthe linear side edges 47 of the rectangular composite structure 33,abutting the front waist edge 38. In particular embodiments, the matingfastening components 84 and 85 have their inner side edges 86 disposedtransversely outward from and closely adjacent to the side edges 76 ofthe absorbent batt 75. Moreover, the leg elastic members 58 aredesirably axially aligned with the mating fastening components 84 and85. The front terminal points 63 of the leg elastic members 58 aredesirably located adjacent inner end edges 87 of the respective matingfastening components 84 and 85, and the back terminal points 65 of theleg elastic members are desirably located adjacent the longitudinallyinnermost parts of the side panels 34.

The first and second mating fastening components 84 and 85 can beadhered to the outer cover 40 by any means known to those skilled in theart such as adhesive bonds, sonic bonds or thermal bonds. In analternative embodiment, the training pant 20 includes only a singlemating fastening component disposed in the front waist region 22 forrefastenably connecting to the first and second fastening components 82and 83 (not shown). In a further alternative embodiment, the outer cover40 and/or bodyside liner 42 functions as a mating fastening component inthat it comprises a material that is releasably engageable with thefirst and second fastening components 82 and 83. In other alternativeembodiments, the fastening components are located on the outer surfaceand the mating fastening components are located on the inner surface.The first and second mating fastening components 84 and 85 are desirablyrectangular, although they may alternatively be square, round, oval,curved or otherwise nonrectangularly shaped.

When the fastening components and the mating fastening components 82-85are releasably engaged, the side edges 36 of the absorbent chassis 32 inthe crotch region 26 define the leg openings 52, and the waist edges 38and 39 of the absorbent chassis, including the waist end edges 72 of theside panels, define the waist opening 50. Due to the composite structure33 being rectangular and the side panels 34 being attached in the backwaist region 24, the side edges 36 of the absorbent chassis 32 in thefront waist region 22 and the crotch region 26 are aligned with oneanother and are parallel to the longitudinal axis 48, that is they formcommon linear edges.

When connected, the fastening components and the mating fasteningcomponents 82-85 form a refastenable seam 88 (FIG. 1). In particularembodiments, each of the fastening components and the mating fasteningcomponents 82-85 define a length dimension that is aligned generallyparallel with the longitudinal axis 48 of the training pant 20 and awidth dimension that is aligned generally parallel with the transverseaxis 49 of the training pant. For a child of about 9 to abut 15kilograms (20-35 lbs.), for example, the length dimension of thefastening components and mating fastening components is desirably fromabout 5 to about 13 centimeters, such as about 10 centimeters, and thewidth dimension is desirably from about 0.5 to about 3 centimeters, suchas about 2 centimeters. The fastening components and the matingfastening components desirably have a length-to-width ratio of about 2or greater, such as about 2 to about 25, and Particularly about 5 orgreater, such as about 5 to about 8. Alternatively, the fasteningcomponents and refastenable seams may be curved or otherwise non-linear.

The refastenable seams 88 desirably extend substantially the entiredistance between the waist opening 50 and the leg openings 52 when thefasteners 82-85 are engaged. More specifically, the refastenable seams88 can cover about 80 to 100 percent, and particularly about 90 to about98 percent, of the distance between the waist opening 50 and each legopening 52, which distance is measured parallel to the longitudinal axis48. To construct the seams 88 to extend substantially the entiredistance between the waist and leg openings 50 and 52, the fasteningcomponents 82 and 83 that are disposed on the side panels 34 can beformed to cover about 80 to 100 percent, and more particularly about 90to about 98 percent, of the distance between the waist end edge 70 andthe leg end edge 72 of the side panels.

The absorbent chassis 32 and the fastening system 80 together define arefastenable pant having a waist opening 50 and a pair of leg openings52. When the fastening system is engaged, it can be appreciated that therefastenable pant includes a pair of refastenable seams 88 extendingfrom the waist opening to each leg opening, a pair of elastomeric sidepanels 34 extending from the waist opening to each leg opening, anelastomeric front waistband 54 disposed in the front waist region andpositioned between the pair of refastenable seams, an elastomeric backwaistband 56 disposed in the back waist region and positioned betweenthe pair of elastomeric side panels, and a pair of elastomeric legmembers 58 which partially encircle each leg opening. Each elastomericleg member 58 extends from adjacent a refastenable seam 88 in the frontwaist region 22 to adjacent an elastomeric side panel 34 in the backwaist region 24.

A single side panel 34 of an alternative disposable absorbent article isshown in FIG. 4. The side panel 34 is bonded to a composite structure 33at an attachment line 66. The side panel 34 includes a distal edge 68transversely spaced from the attachment line 66 and a leg end edge 70and a waist end edge 72 that extend from the composite structure to thedistal edge. The side panel 34 illustrated in FIG. 4 includes a separatefirst member 90, second member 92, and third member 94 that are arrangedin series from the attachment line 66 to the distal edge 68. Thefastening component 83 is disposed on the third member 94 adjacent thedistal edge 68.

The first member 90 and the second member 92 are desirably attached toone another at a manually tearable seam 96 that extends from the leg endedge 70 to the waist end edge 72. The tearable seam 96 is desirablyformed of suitable means such as ultrasonic bonds that permit the sidepanel 34 to be torn easily at or along the tearable seam by thecaregiver. The tearable seam 96 is desirably but not necessarily anoutwardly directed fin seam. The second member 92 and the third member94 are desirably attached to one another at a permanent seam 98 thatextends from the leg end edge 70 to the waist end edge 72. The permanentseam 98 may be formed by adhesives, sonic or thermal bonds, or somecombination thereof and is designed to resist tearing. In particularembodiments, the first and second members 90 and 92 comprise elastomericmaterials and the third member 94 comprises a non-elastomeric material.Alternatively, the side panel may comprise two members, one or both ofwhich may be elastomeric, that are bonded together at either a tearableseam or a permanent seam (not shown). A training pant incorporating theside panel 34 illustrated in FIG. 4 comprises a pair of refastenableseams and a pair of manually tearable seams 96.

An alternative training pant 300 is illustrated in a stretched and laidflat condition in FIG. 5. The training pant 300 includes first andsecond mating fastening components 84 and 85 disposed in the front waistregion 22 on the outer surface 30. The training pant 300 also includes apanel member 302 disposed in the back waist region 24. The panel member302 desirably forms first and second side panels 304 and 306 that extendtransversely outward from the composite structure 33 and the absorbentassembly 44 (FIG. 3) in the back waist region 24. First and secondfastening components 82 and 84 of the training pant 300 are bonded tothe inner surface 28 of the side panels 304 and 306.

The panel member 302 can comprise an integral portion of a component ofthe composite structure 33, such as the bodyside liner 42 or a layer ofthe outer cover 40; or comprise a separate element bonded to thecomposite structure; or comprise a plurality of layers, whether integralportions, separate elements, or a combination thereof. The panel member302 and thus the side panels 304 and 305 can comprise either an elasticmaterial or an inelastic material. With additional reference to FIG. 6,the panel member 302 in the illustrated embodiment comprises a pluralityof elastomeric segments 310 disposed between an outer facing layer 312and an inner facing layer 314.

The elastomeric segments 310 can be positioned and arranged so that bothside panels 304 and 305 have elastic properties in a direction parallelto the transverse axis 49 of the training pant 300. The elastomericsegments 310 can comprise elastomeric films, webs, strands, fibers orthe like, and can comprise elastic materials similar to those describedin relation to other elastic components of the training pants 20 and300. The facing layers 312 and 314 can comprise materials of the typedescribed in relation to the bodyside liner 42, the side panels 34, orthe like.

An enlarged plan view of a back side panel 34 of the type shown in FIG.1 is illustrated in FIG. 7. Only one side panel 34 is shown in FIG. 7,although it should be understood that other side panels can employ asimilar construction. The side panel 34 can be bonded to and extendtransversely beyond the linear side edge 47 of the composite structure33 along attachment line 66. The side panel 34 defines a distal edge 68that is spaced from the attachment line 66, a leg end edge 70 disposedtoward the longitudinal center of the training pant 20, and a waist endedge 72 disposed toward a to longitudinal end of the training pant.Alternatively, the side panels can comprise an integral portion of acomponent of the composite structure 33, such as the bodyside liner orthe outer cover.

In particular embodiments, the fastening component 83 is spaced inwardfrom the distal edge 68 and the end edges 70 and 72 in order to protectthe wearer from irritation that might be caused by contact with thefastening component. Specifically, the fastening component 83 can bespaced transversely inward from the distal edge 68 in the region ofreference numeral 100. Also, the fastening component 83 can be spacedlongitudinally inward from the leg end edge 70 in the region ofreference numeral 102, and spaced longitudinally inward from the waistend edge 72 in the region of reference numeral 104.

The degree of spacing balances the fact that a smaller distance isharder for children and parents to remove but provides a moregarment-like appearance, while a larger distance is easier for childrenand parents to remove but provides a loose and floppy appearance that isnot garment-like. Thus, the fastening component 83 is desirably spacedtransversely inward from the distal edge 68 by about 1 to about 15millimeters, particularly about 1 to about 5 millimeters, such as about2 millimeters. The fastening component 83 is desirably spacedlongitudinally inward from the leg end edge 70 and from the waist endedge 72 by about 2 millimeters or more, particularly about 5 millimetersor more, such as from about 5 to about 15 millimeters.

FIG. 8 illustrates an enlarged plan view of a front waist region 22including a mating fastening component 85. As with the embodimentillustrated in FIG. 7, the fastening component 85 can be spacedtransversely inward from the side edge 36 in the region of referencenumeral 100 and longitudinally spaced inward from the end edge 45 in theregion of reference numeral 104. The preferred distances from the edgesare the same as those specified above in relation to the embodiment ofFIG. 7.

The training pants 20 and 300 may further include releasable side bonds(not shown) for improved reliability of maintaining the pant in aprefastened condition particularly when it is being pulled on or offover the hips of the wearer. Such releasable side bonds are desirablyconfigured to be readily broken such that the caregiver can easilyremove the training pant 20 after it has been soiled. The releasableside bonds desirably comprise ultrasonic point bonds. Absorbent articlesincluding such releasable side bonds are further described in U.S.patent application Ser. No. 09/100,574 titled “Disposable AbsorbentArticles Having Passive Side Bonds And Adjustable Fastening Systems”filed Jun. 19, 1998 by Elsberg, which is incorporated herein byreference.

The methods of the different aspects of the present invention aredirected at reliably and consistently providing the refastenabletraining pants 20 and 300 as described herein and representativelyillustrated in the Figures. The various components of the training pant20 are integrally assembled together employing various types of suitableattachment means, such as adhesive, sonic and thermal bonds orcombinations thereof.

It will be appreciated that details of the foregoing embodiments, givenfor purposes of illustration, are not to be construed as limiting thescope of this invention. Although only a few exemplary embodiments ofthis invention have been described in detail above, those skilled in theart will readily appreciate that many modifications are possible in theexemplary embodiments without materially departing from the novelteachings and advantages of this invention. Accordingly, all suchmodifications are intended to be included within the scope of thisinvention, which is defined in the following claims and all equivalentsthereto. Further, it is recognized that many embodiments may beconceived that do not achieve all of the advantages of some embodiments,particularly of the preferred embodiments, yet the absence of aparticular advantage shall not be construed to necessarily mean thatsuch an embodiment is outside the scope of the present invention.

1. An absorbent article, comprising: an absorbent chassis comprising a bodyside liner, an outer cover bonded to the bodyside liner, and an absorbent assembly disposed between the bodyside liner and the outer cover, the absorbent chassis defining a longitudinal axis, a transverse axis, an overall length dimension, first and second waist edges parallel to the transverse axis, opposite side edges extending between the first and second waist edges, a first waist region contiguous with the first waist edge, a second waist region contiguous with the second waist edge, and a crotch region which extends between and interconnects the first and second waist regions, the side edges in the first waist region and crotch region being aligned with one another parallel to the longitudinal axis; first and second side panels extending transversely outward from the absorbent assembly in the second waist region, the side panels having opposite edges and an average length dimension that is about 20 percent or greater of the overall length dimension; leg elastic members longitudinally aligned along each side edge; and a fastening system for releasably securing the absorbent article in a pant-like configuration, the fastening system comprising first and second fastening components adapted to releasably engage first and second mating fastening components, each of the fastening components and the mating fastening components having a length dimension aligned generally parallel to the longitudinal axis, a width dimension, and a length-to-width ratio of about 5 or greater, the fastening components being disposed on the side panels and covering about 80 to 100 percent of the distance between the opposite edges of the side panels, the mating fastening components being disposed in the first waist region along the opposite side edges abutting the first waist edge, the leg elastic members being axially aligned with the mating fastening components.
 2. The absorbent article of claim 1, wherein each leg elastic member has a front terminal point and a back terminal point, the front terminal points being located adjacent inner end edges of the respective mating fastening components.
 3. The absorbent article of claim 2, wherein the front terminal points are located within about 2 centimeters of the mating fastening components.
 4. The absorbent article of claim 2, wherein the back terminal points are located adjacent longitudinally innermost parts of the side panels.
 5. The absorbent article of claim 4, wherein the back terminal points are located within about 2 centimeters of the longitudinally innermost parts of the side panels.
 6. The absorbent article of claim 1, wherein each side panel is elastomeric from a waist end edge to a leg end edge.
 7. The absorbent article of claim 1, wherein the absorbent assembly includes an absorbent batt having opposite side edges generally longitudinally oriented within the absorbent chassis, and the mating fastening components have inner side edges disposed transversely outward from and adjacent to the side edges of the absorbent batt.
 8. An absorbent article, comprising: a generally inelastic absorbent chassis comprising a bodyside liner, an outer cover bonded to the bodyside liner, and an absorbent assembly disposed between the bodyside liner and the outer cover, the absorbent chassis defining a longitudinal axis, a transverse axis, first and second waist edges parallel to the transverse axis, opposite side edges extending between the first and second waist edges, a first waist region contiguous with the first waist edge, a second waist region contiguous with the second waist edge, and a crotch region which extends between and interconnects the first and second waist regions; first and second elastomeric side panels extending transversely outward from the absorbent assembly in the second waist region; and a fastening system for releasably securing the absorbent article in a pant-like configuration, the fastening system comprising first and second fastening components adapted to releasably engage first and second mating fastening components, the fastening components being disposed on the elastomeric side panels and having a length dimension, a width dimension, and a length-to-width ratio of about 2 or greater, the mating fastening components being disposed on the generally inelastic absorbent chassis in the first waist region and positioned along the opposite side edges abutting the first waist edge, the mating fastening components having a length dimension, a width dimension, and a length-to-width ratio of about 2 or greater wherein each first and second fastening component has a length-to-width ratio of about 5 or greater.
 9. The absorbent article of claim 8, further comprising leg elastic members longitudinally aligned along each side edge and axially aligned with the mating fastening components.
 10. The absorbent article of claim 8, further comprising leg elastic members longitudinally aligned along each side edge, each leg elastic member having a front terminal point and a back terminal point, the front terminal points being located within about 2 centimeters of inner end edges of the respective mating fastening components.
 11. The absorbent article of claim 10, wherein the back terminal points are located adjacent longitudinally innermost parts of the side panels.
 12. The absorbent article of claim 8, wherein each side panel is elastomeric from a waist end edge to a leg end edge.
 13. The absorbent article of claim 8, wherein the absorbent assembly includes an absorbent batt having opposite side edges generally longitudinally oriented within the absorbent chassis, and the mating fastening components have inner side edges disposed transversely outward from and adjacent to the side edges of the absorbent batt.
 14. The absorbent article of claim 8, wherein the side edges in the first waist region and crotch region are aligned with one another and are parallel to the longitudinal axis.
 15. The absorbent article of claim 8, wherein the mating fastening components have a length dimension aligned generally parallel to the longitudinal axis, a width dimension, and a length-to-width ratio of about 5 or greater.
 16. An absorbent article, comprising a generally inelastic absorbent chassis and a fastening system for releasably attaching a front waist region of the absorbent chassis to a back waist region of the absorbent chassis to define a refastenable pant having a waist opening and a pair of leg openings, the refastenable pant comprising: a pair of refastenable seams extending from the waist opening to each leg opening; a pair of elastomeric side panels extending from the waist opening to each leg opening; an elastomeric front waistband disposed in the front waist region and positioned between the pair of refastenable seams, at least part of the front waistband being transversely axially aligned with the pair of refastenable seams; an elastomeric back waistband disposed in the back waist region and positioned between the pair of elastomeric side panels; and a pair of elastomeric leg members which partially encircle each leg opening, each elastomeric leg member extending from adjacent a refastenable seam in the front waist region to adjacent an elastomeric side panel in the back waist region.
 17. The absorbent article of claim 7, wherein the mating fastening components abut the respective opposite side edges of the absorbent chassis.
 18. The absorbent article of claim 13, wherein the mating fastening components abut the respective opposite side edges of the generally inelastic absorbent chassis.
 19. The absorbent article of claim 16, wherein the fastening system comprises first and second fastening components adapted to releasably engage first and second mating fastening components, the fastening components being disposed on the elastomeric side panels and having a length dimension, a width dimension, and a length-to-width ratio of about 2 or greater, the mating fastening components being disposed on the generally inelastic absorbent chassis in the front waist region and positioned along opposite side edges of the generally inelastic absorbent chassis and abutting a front waist edge of the front waist region, the mating fastening components having a length dimension, a width dimension, and a length-to-width ratio of about 2 or greater. 